Exploiting Advanced Manufacturing Capabilities: Topology Optimization in Design Proceedings of a Workshop (2022) / Chapter Skim
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3 Topology Optimization and Advanced Manufacturing Technologies
3 Topology Optimization and Advanced Manufacturing Technologies
Pages 13-25
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From page 13... ...
Doing so will require understanding manufacturing realities, maintaining physical meaning, and pursuing new directions.
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From page 14... ...
additive manufacturing, build direction, feature sizes, and layer height must also be considered. Design optimality is ultimately dependent on the build direction: that is, building from the bottom up may require a very differ ent design than building from the top down, as does choosing different feature sizes and layer heights.
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From page 15... ...
Using this approach guarantees that a converged design can be manufactured using the specified process. Recent Work and Future Directions Guest shared a few examples of his work and discussed promising advancements toward additive manufacturing, carbon nanotube yarns, architected materials, and 3D woven materials.
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From page 16... ...
, and he detailed several custom advanced manufacturing technolo gies. LLNL views additive manufacturing as part of an ecosystem of sophisticated fabrication systems that begins with design, moves into synthesis of materials, incorporates the manufacturing process itself, and finishes with qualification and certification to ensure performance.
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From page 17... ...
While LiDO is currently used only for research, Spadaccini said that it should be more widely applicable soon. Spadaccini's team has used LiDO to design architected materials for various projects, such as microscale trusses, a bridge design infilled with lattices, and struc tures to respond to transient phenomena such as load speed or impact.5,6 Current and Future Manufacturing Technologies Spadaccini described several manufacturing technologies used or developed at LLNL over the past decade.
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From page 18... ...
Designer "inks" are extruded and used to create complex designs written in silicone, graphene aerogel, nanoporous gold, glass, or printed carbon fiber. Spadaccini described several promising future technologies, including volu metric additive manufacturing, which would create an entire 3D structure in one operation through the superposition of light beams, akin to a hologram (but not actually a hologram)
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From page 19... ...
Understanding the Printing Process To achieve consistent performance, it is critical to understand what happens during the printing process, such as the heat transfer described above, and how that affects the final product, Begley said. The topology optimization "engine" to achieve consistent performance requires accurate performance predictions of a candidate design based on many properties, including cell type, porosity, and shape.
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From page 20... ...
In all designs, tradeoffs must be made, and in general, all materials systems and processing require a certain level of control for acceptable performance. PANEL DISCUSSION ON THE EMERGING SYNERGY BETWEEN TOPOLOGY OPTIMIZATION, MANUFACTURING, AND MATERIALS Faber introduced the three speakers who had been invited to address the synergies between topology optimization, manufacturing, and materials: Claus Pedersen, Dassault Systèmes Simulia Corp; David Chapin, GE Additive; and Jonathan Berger, Nama Development LLC.
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From page 21... ...
In addi tion, the team did not stop at design, but brought the work all the way through computer-aided design (CAD) modeling using automated CAD-reconstruction and validations including additive manufacturing process simulation validation.
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From page 22... ...
The final speaker was Jonathan Berger, who discussed his research identify ing a fabricable geometry that can attain Hashin-Shtrikman theoretical upper bounds for lightweight stiffness.12 In addition, he has identified two other material mesostructures, one with a maximum shear modulus and one with a maximum Young's modulus, both under the conditions of cubic symmetry, as two other high performance unit cell designs. Similarly, he has found that with the right combination of geometries, it is pos sible to design an isometric material geometry with good performance, achieving the upper bounds, that could be created using additive manufacturing.
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From page 23... ...
Reinhard Radermacher, University of Maryland, asked the panel what the smallest feasible feature size was, both today and in the future. Chapin responded that the answer depended on what technology was being used, but that with laser powder bed fusion printing techniques his team has demonstrated the ability to achieve features smaller than 10 thousandths of an inch thick.
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From page 24... ...
He sees additive manufacturing as very valuable if it can evolve to the point where designing, building, and testing is quick and inexpensive. Verification and validation testing inspire confidence in a product, he continued, and it is possible to learn methods from other agencies or fields.
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From page 25... ...
Right now, he suggested, the best way forward is to avoid wading through all the complexities and interactions that can exist in additive manufacturing, which cannot be addressed simultaneously or generically, and identify a tractable problem with manageable elements and clear economic gains. Chapin stressed the importance of reducing the time required to characterize new materials.
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